Manufacturing plant for parts, particularly vehicle body parts

ABSTRACT

A manufacturing plant ( 1 ) is provided for vehicle body parts ( 2, 3 ). The manufacturing plant includes a number of processing stations ( 4, 5, 6, 7, 8, 9, 10 ), which are situated one behind the other along a transfer line ( 22 ), and of a number of multiaxial robots ( 18, 19 ). In at least one processing station ( 4, 5, 6, 7, 8, 9, 10 ), one or more handling robots ( 18 ) for transporting parts is/are arranged on at least one axis of travel ( 20, 21 ). Next to the handling robot ( 18 ), one or more processing robots ( 19 ) is/are displaceably arranged on the same axis of travel ( 20 ). Working locations ( 11, 12 ) are arranged on both sides of a common axis of travel ( 20 ), whereby another common axis of travel can be provided on the rear side of the working locations.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a United States National Phase application ofInternational Application PCT/EP2003/014766 and claims the benefit ofpriority under 35 U.S.C. §119 of German Application DE 203 04 022.8filed Mar. 12, 2003, the entire contents of which are incorporatedherein by reference.

FIELD OF THE INVENTION

The present invention pertains to a manufacturing plant for components,especially body parts.

BACKGROUND OF THE INVENTION

Such a manufacturing plant is known from DE 298 04 850 U1.It comprises aplurality of processing stations or cells, which are arranged in a rowalong a transfer line. A central transport robot, which is designed as astationarily positioned multiaxial articulated arm robot and transportsthe parts, is present within each cell. Within the cell, there are aplurality of work stations, at which the parts are processed, especiallyjoined, by processing robots. The parts are transferred between thecells via intermediate storage units at the common cell boundaries.Relatively many robots are needed in such cells, and, moreover, theserobots are not utilized optimally.

SUMMARY OF THE INVENTION

The object of the present invention is to provide an improvedmanufacturing plant.

According to the invention, a manufacturing plant is provided forcomponents, especially body parts. The plant comprising a plurality ofprocessing stations, which are arranged one after another along atransfer line and a plurality of multiaxial robots. One or more of thehandling robots is provided for transporting the parts and are arrangedin at least one processing station on at least one travel axis.

The arrangement of one or more handling robots on additional travel axesexpands the working range and improves the operation as well as theability to reach work stations, which are arranged as multiple workstations within one processing station. This is advantageous above allfor a flexible manufacturing plant, in which different types of partsare processed in a preferably free mix, the work stations being relatedto the particular type. Despite the enlargement of the working range ofthe robot and the increase in the number of work stations, the number ofhandling robots needed can be kept low.

It is particularly advantageous if handling and processing robots arearranged next to one another on a common travel axis. As a result,processing and handling operations, especially transport operations, cantake place simultaneously, and, moreover, a plurality of parts can beprocessed and/or handled simultaneously. Due to the common travel axis,the total number of robots needed can in turn be kept low. One or morerobots may also have a dual function as a handling robot and as aprocessing robot.

The processing stations may be arranged separated from one another, inwhich case transfer points with intermediate storage units, bufferstorage units or the like are formed in the transfer line. The transferline may, moreover, branch out, which makes possible the betterutilization of the individual processing stations. As a result, thepreset cycle time and the flow of material can, in addition, be madeflexible.

As an alternative, it is possible to arrange one or more common travelaxes through a plurality of processing stations adjoining one another,as a result of which a smooth transfer from one station to the next iscreated. Such a design has, moreover, advantages in case of a highdegree of making the manufacturing plant flexible. The design effortsand the transfer times between the individual stations are optimized.

The present invention is schematically represented as an example in thedrawings. The various features of novelty which characterize theinvention are pointed out with particularity in the claims annexed toand forming a part of this disclosure. For a better understanding of theinvention, its operating advantages and specific objects attained by itsuses, reference is made to the accompanying drawings and descriptivematter in which a preferred embodiment of the invention is illustrated.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a top view of a manufacturing plant with a plurality ofprocessing stations arranged one after another along a transfer line;

FIG. 2 is an enlarged and cut-away detail of an individual processingstation from the manufacturing plant in FIG. 1;

FIG. 3 is an enlarged and cut-away detail of an individual processingstation from the manufacturing plant in FIG. 1; and

FIG. 4 is an enlarged and cut-away detail of an individual processingstation from the manufacturing plant in FIG. 1.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the drawings in particular, FIG. 1 schematically shows atop view of a manufacturing plant (1) for components (2, 3), which arepreferably body parts of vehicle bodies, especially body shells. Thesemay be, e.g., the shown side panels of a vehicle body. A plurality ofdifferent types of parts (2, 3) of the same kind can be preferablyprocessed in the manufacturing plant (1) next to one another andpreferably in a free mix. Two different types of parts (2, 3) are shownin the embodiment shown. Measures are taken here to also make itpossible to process three or more or any other desired number of typesof parts.

The manufacturing plant (1) comprises a plurality of processing stations(4 through 10), which are arranged one after another along a transferline (22). The parts (2, 3) are processed in the individual stations (4through 10) and then passed on from station to station. The transferline (22) may have any desired shape and extension. It may have a lineardesign at least in some areas, in which case a plurality of processingstations, e.g., stations (4, 5), are arranged directly one after anotherin an aligned line. As an alternative, the transfer line (22) may alsohave kinks, in which case transfer points (13) with a change in thedirection of conveying are formed, e.g., between the stations (5, 6, 7).Unlike in the simple exemplary embodiment being shown, it is,furthermore, possible for the transfer line (22) to branch out in someareas. As a result, e.g., two or more processing stations may bearranged in parallel next to one another and fed alternatingly from thetransfer line. Such a design is suitable, for example, in case of cycletime-intensive stations, in which the processing takes longer than inthe other stations. After the branching, the transfer line (22) mayagain unite in one line. A plurality of parallel transfer lines (22) arealso possible in another modification.

A plurality of robots (18, 19) each, which are preferably multiaxialarticulated arm robots, especially industrial robots with six axes, arearranged in the processing stations (4 through 10). At least some of therobots (18, 19) are arranged on an additional travel axis (20, 21) andcan move on that axis through the individual processing stations (4, 5,7, 8, 9). A plurality of robots (18, 19) are arranged next to oneanother on one travel axis (20, 21) at least in some areas.

The robots (18, 19) may have assigned task areas. These are handlingrobots (18), on the one hand, which perform transport and handlingtasks. On the other hand, processing robots (19) are present, whichcarry out any processing of parts, e.g., joining operations. Many of therobots (19) are, for example, welding robots. One or more robot (18, 19)may have change couplings on the robot hand in order to change toolswhen needed. A handling robot (18) can also perform processing tasks inthis case at the parts (2, 3) due to a tool change. The robots (18, 19)can be better utilized and offer an added economic value due to such adual function of handling and processing.

Type-specific processing of the different parts (2, 3) is possible indifferent processing stations (4, 5, 7, 8, 9). A plurality oftype-specific work stations (11, 12), which are designed, e.g., astype-specific part supports with special clamping devices, are presentfor this purpose in these processing stations (4, 5, 7, 8, 9). Thesework stations (11, 12) are arranged along the travel axes (20, 21) andcan be operated jointly by the robots (18, 19).

At least one common travel axis (20), on which one or more handlingrobots (18) and one or more processing robots (19) are arranged next toone another, is arranged in one or more processing stations (4, 5, 7, 8,9). The work stations (11, 12) are preferably arranged along this commontravel axis (20), so that all robots (18, 19) can reach all workstations (11, 12). The common travel axis (20) preferably extends alongthe transfer line (22).

Furthermore, one or more additional travel axes (21), which preferablyextend in parallel to the common travel axis (20) and on which one ormore robots, preferably processing robots (19), are mounted movably, maybe present in one or more processing stations (4, 5, 7, 8, 9).

The travel axes (20, 21) may have any desired suitable design. In theembodiment being shown, they are travel rails, which form the seventhrobot axis. The robots (18, 19) have corresponding traveling gears forthis. In addition, suitable positioning means are present to exactlyposition the robots at the work stations (11, 12).

FIG. 2 shows a top view of the entry area of the manufacturing plant(1). The first processing station (4) is designed as a loading stationwith a plurality of work stations (11, 12), which are designed asloading points (14) in this case. The different types of parts (2, 3)can be placed here by one or more workers (24) manually on supports thatdetermine the suitable geometry and clamped. Suitable safety means forthe worker (24), e.g., step-activated switching mats, which send acorresponding signal to the robot and plant control when stepped on andinterrupt the robot drive during the manual insertion by the worker(24), may be present in this case at the loading points (14) or workstations (11, 12).

The common travel axis (20) is arranged along the work stations (11,12). A handling robot (18) and a processing robot (19), for example, awelding robot, move next to one another on the common travel axis (20).The welding robot (19) performs the first welding operations on theparts (2, 3) inserted manually at the loading points (14). The handlingrobot (18) takes over the parts (2, 3) after the completion of theprocessing and transports them farther into the next processing station(5), which is designed as a so-called respot station for the furtherwelding of the initial tacked parts (2, 3).

The processing stations (4, 5) have a common, continuous travel axis(20) reaching over several stations in this case. As a result, theabove-mentioned handling robot (18) can remove the parts (2, 3) from theloading station (4) and bring them directly to the different,type-specific work stations (11, 12) of the respot station (5) anddeposit them there. A second handling robot, which ensures the handlingthe parts (2, 3) in the respot station (5) and, furthermore, the furthertransportation into the next processing station (6), may be arranged onthe common travel axis (20) at the downstream end.

For example, four work stations (11, 12) are arranged in the respotstation (5) on both sides of the common central travel axis (20). Forclarity's sake, only two of the four work stations (11, 12) are shown inthe operating position and with parts (2, 3). As an alternative, thenumber of work stations (11, 12) may also vary upward or downward. Thework stations may also be arranged on one side of the travel axis (20)only.

The processing robots (19) are arranged in the respot station (5) on twoadditional travel axes (21), which extend along the other rear side ofthe work stations (11, 12) and in parallel to the common travel axis(20). Furthermore, there also may be additional travel axes in avariant, not shown, which are directed crosswise or in another way andare arranged between the work stations (11, 12) and/or at the front endsthereof. One or more processing robots (19) are arranged in adisplaceable manner on these one or more additional travel axes (21).

The handling and processing robots (18, 19) can be separated from oneanother in space in case of this arrangement, in which case onlyhandling robots (18) are arranged, e.g., on the inner travel axis (20)and only processing robots (19) are arranged on the outer or lateraltravel axis or travel axes (21). The running production does not need tobe stopped in case of a change from one model to the next or in case ofan increase in the number of models. Only one or more work stations areretrofitted while the operation continues to run without utilization atthe other work stations (11, 12). This configuration of the plant may beused in case of other stations as well.

At the loading and respot station (4, 5), the common travel axis (20)forms the transfer line (22), and a transfer point (13) is formed with aline offset at the end of the respot station (5). A third processingstation (6), which is designed, e.g., as a sealer station, which has adelivery table (16) common for all types of parts (2, 3) and also formsthe intermediate storage unit (17) for the transfer of the parts and forthe further transportation, is arranged at the transfer point (13). Thehandling robot (18) arranged at the end of the common travel axis (20)places the parts (2, 3) welded in the respot station (5) on the deliverytable (16), and a sealer and a sealing compound or another material issubsequently applied by a processing robot (19), which is arranged,e.g., stationarily, or another processing of the part, which ispreferably tolerant or neutral with respect to the type, is carried out.

The next processing station (7) is again designed as a welding stationand is arranged offset and separated from the loading and respot station(4, 5). There are two common travel axes (20) in the welding station(7), which are arranged on both sides along a row of work stations (11,12). Handling and processing robots (18, 19) are arranged displaceablynext to each other on both common travel axes (20).

As is illustrated by the transfer point (13) with the intermediatestorage unit (17) between the two processing stations (5, 7), a handlingrobot (18) each, whose working range covers the intermediate storageunit (17), is arranged on the common travel axis (20) of these adjacentstations (5, 7) at the ends. The handling robots (18) thus ensure thetransport of the parts at the transfer point (13), bridging over theoffset of the lines.

Furthermore, a loading point (14), which is operated by a worker (24)manually, and at which additional small parts or the like are fed andjoined with the parts (2, 3), may be present at the welding station (7).On the one hand, the individual handling robot (18) arranged on theupper common travel axis (20) takes over the parts (2, 3) from thesealer station (6) and transports them to the work stations (11, 12) inthe welding station (7). In addition, this handling robot (18)transports the additional parts from the loading point (14) to the parts(2, 3) on the work stations (11, 12). The total of three welding robots(19) arranged on the two common travel axes (20) carry out the necessaryjoining and welding operations on the parts (2, 3) and can reach allwork stations (11, 12) for this. An individual handling robot (18),which removes the parts (2, 3) after the welding and brings them to thetransfer point (13) for the further transportation, is arranged, inturn, displaceably on the second lower, common travel axis (20) at thedownstream end.

The welding station (7) is joined by a buffer storage unit (15), whichis designed, e.g., as a belt type storage unit running about verticalaxes. It is operated by the above-mentioned handling robot (18) on thelower travel axis (20).

The buffer storage unit (15) is joined by another processing station (8)in the form of a welding station, which has a design similar to that ofthe above-described welding station (7). Two travel axes (20, 21) arelikewise arranged here in parallel and on both sides of a row of workstations (11, 12). FIGS. 3 and 4 show this design of the station with asection line at right angles through the station. Two handling robots(18), which operate independently from one another and also operate amanual loading point (14), at which a worker (24) inserts additionalparts to the parts (2, 3), are arranged on the upper travel axis (20) inthis case. The upstream handling robot (18) takes over, furthermore, theparts (2, 3) from the buffer storage unit (15). The downstream handlingrobot (18) ensures the further transportation to an intermediate storageunit (17), which forms the next transfer point (13). Three weldingrobots (19) are arranged on the lower travel axis (21) displaceablyindependently from one another in the welding station (7) in this case.

The adjoining processing station (9) is another welding station, inwhich the working stations (11, 12) are arranged on both sides of acentral travel axis (20), on which two handling robots (18) aredisplaceable independently from one another. The welding robots (19) arepositioned on two more travel axes (21) in a triple arrangement each,which extend along the rear sides of the work stations (11, 12). Thedownstream handling robot (18) takes over the parts (2, 3) from thewelding station (9) after the conclusion of the welding operations andtransports them to an unloading station (10), in which the transfer to aparts conveyor (23) takes place, with which the parts (2, 3) areremoved.

Various modifications of the embodiment shown are possible. Thus, thenumber, the arrangement and the design of the individual processingstations may vary as desired. This also applies to the number and thearrangement of the travel axes (20, 21) and the robots (18, 19). Thetype of the processing operations and the design of the transfer pointsor interfaces are likewise selectable as desired.

While specific embodiments of the invention have been shown anddescribed in detail to illustrate the application of the principles ofthe invention, it will be understood that the invention may be embodiedotherwise without departing from such principles.

1. A manufacturing plant for body part components, the manufacturing plant comprising: a plurality of processing stations, which are arranged one after another along a transfer line, and a plurality of multiaxial robots, wherein one or more handling robots for transporting the parts are arranged in at least one processing station on at least one travel axis, which extends through a plurality of adjacent processing stations and connects same, and at least one of the processing stations has a plurality of, type-specific work stations for different types of parts of the same kind and one or more additional travel axes for one or more robots, wherein the additional travel axis is arranged on the other side of the work stations and the type-specific work stations are arranged next to one another along the travel axes and can be operated by the robots.
 2. A manufacturing plant in accordance with claim 1, wherein said one or more handling robots and one or more processing robots are arranged movably next to one another on one or more common travel axes.
 3. A manufacturing plant in accordance with claim 1, wherein the work stations are arranged both sides of a common travel axis.
 4. A manufacturing plant in accordance with claim 1, wherein the work stations can be operated jointly by the handling robots and the processing robots.
 5. A manufacturing plant in accordance with claim 1, wherein transfer points with intermediate storage units, which are located in the working range of the handling robots, are arranged between the processing stations.
 6. A manufacturing plant in accordance with claim 1, wherein a handling robot each is arranged on a common travel axis of adjacent processing stations at ends thereof.
 7. A manufacturing plant in accordance with claim 1, wherein one or more processing robots are arranged on the common travel axis between the end-side handling robots.
 8. A manufacturing plant in accordance with claim 1, wherein the robots are designed as multiaxial articulated arm robots.
 9. A manufacturing plant in accordance claim 1, wherein the robots have a dual function as a handling robot and as a processing robots. 